RU2749103C1 - Industrial programmable controller - Google Patents

Abstract

FIELD: controllers.SUBSTANCE: invention relates to programmable logic controllers. The programmable controller (1) comprises a processing unit (2), no less than one local section (3) comprising no less than one chassis (8) with input-output modules (9), and no less than one remote section (4) comprising no less than one chassis (10) with no less than one interface module (11) and input-output modules (12). The processor unit (2) is comprised of a chassis (5) and a central processing unit module (6) (CPU module) fixed on the chassis or two reserved CPU modules fixed on the chassis. The chassis has interface connectors intended for buses (14) intended for communication with the chassis (8) of the local section (3) on the front wall thereof. Each CPU module has interface connectors intended for buses (15) for communication with the interface module (11) of the remote section (4) intended for buses (17) for communication with the upper level system (16) of the APCS on the front wall thereof. The two interface connectors on the front of the CPU module take form of SFP modules.EFFECT: ensured possibility of using input-output modules of different series of controllers.1 cl, 6 dwg

Description

The invention relates to an industrial programmable controller MFK 1500 ^® . The industrial programmable controller (hereinafter referred to as the controller) is intended for measurement, control, regulation, diagnostics and control of production processes, technological lines and units of medium and high complexity, both in process control systems and in emergency protection and interlocking systems.

The processor unit of the controller consists of a chassis and two redundant central processing units (hereinafter referred to as CPU modules) fixed to the chassis.

It should be clarified that the term "connector" is used when describing analogs and a utility model in a general sense and covers device sockets and / or plugs, ports, connectors, clamps, optical SFP modules, etc.

It is worth clarifying that the term "interface connector" is used in the application when describing analogs and a utility model in relation to connectors intended for interaction of subscribers via an interface.

It is worth clarifying that the term "input-output module" is used when describing analogs and a utility model in a general sense and covers all possible communication devices with an object (USO) intended for inputting signals from sensors of various types into the controller, as well as for outputting control signals executive devices, and working with various types of signals, including input and / or output modules for analog and / or discrete signals, input of number-pulse and frequency signals, etc.

The design of the controller modules should ensure their location in standard electrical cabinets. Several form factors of controller modules are known. Some have the form of separate functional modules, the cases of which are mounted on a DIN rail, and communication between the modules occurs via cables. Controllers are widespread, the printed circuit boards of the modules of which and the backplane are located in a crate and have a Euromechanics construct. Recently, controllers have the appearance of separate functional modules, the cases of which are made of plastic and fixed to the chassis, while each of the companies uses its own standard sizes, shapes and designs of modules and chassis. Communication between modules in such controllers is carried out via an internal bus located on the chassis printed circuit board. All of the above series ¹ controllers have been developed in the group TEKON companies and today in the design of the PTC ² TEKON for process automation can be used the entire line of controllers (TEKONIK ^®, MFK3000 ^®, MFK1500 ^® based CPU CPU715 series module), each of which to the greatest extent intended for solving local problems.

Pages 1-5 of brochure ³ , Product Information. Family Experion ^® I / O »and on page 24 of the brochure ^4," Overview of controllers and input-output modules Experion ^® CEE "describes a series of IO modules developed by Honeywell. These are the Rail I / O Series-A (RIOM-A) and Rail I / O Series-H (RIOM-H), which are designed for mounting on a DIN rail. This is the PM I / O (PMIO) series, the printed circuit boards of the modules of which and the backplane are located in the crate. This is also the Chassis I / O Series-A (CIOM-A), whose module cases are fixed to the chassis. This is the "Series C" series, in which each of the I / O module housings and the control module housing are located on its own individual printed circuit board. All series of Honeywell modules were created as part of the creation of new controllers in which the form factor of the control module corresponded to the form factor of the I / O modules. Honeywell's vision in Brochures ^{3 and 4} is that by designing the Experion Process Knowledge System (Experion PKS ^® ), a distributed process control system, the user can use all five series of I / O modules to choose from. the solution most suitable for managing a specific process. At the same time, Experion PKS proposes to use the most powerful C200 or C300 control modules as central computing devices. At the same time, I / O modules of different series can be used with the same control module, which allows for maximum flexibility at the lowest cost of the control system.

The possibility of designing a flexible Experion PKS ^® control systems provide the following factors:

- Five fully integrated series of I / O modules in a variety of form factors and mounting methods, with each series offering a complete set of functions, characteristics and module types.

- All series of I / O modules are fully integrated with the control module and user interface.

In this design the flexible Experion PKS ^® control system provides the following advantages:

- Support for legacy input-output module enables users to protect their investments and develop into Experion PKS ^® at a pace that is best suited for their businesses and staff.

- Ability to integrate with field networks and smart digital device protocols (such as HART, FOUNDATION Fieldbus, ProfiBus, Modbus, DeviceNet).

- Selectively, some networks and I / O modules can be implemented in a redundant configuration that does not provide a single point of failure.

The design of the Honeywell C300 processor module (page 21 of brochure ⁴ ), which was later named "C300 controller" (brochure ⁵ "Experion C300 Controller"), allows it to be connected to I / O modules of different series of controllers. The C300 processor module consists of a "Series C" control module and its individual board (individual chassis). All interface connectors for connecting the control module to all external devices and power supply are located only on its individual board. The control module itself does not contain interface connectors for connecting external devices. But a rectangular individual board has a sufficiently large perimeter, which allows you to place the required number of different types of connectors on it. In the electrical cabinet, the individual boards are placed one under the other. In this case, only one control module is located on one individual board. With redundancy, the second control module is located on its own individual board, and communication between the redundant control modules occurs via cables that connect their boards. ^{Brochure 5} notes that the form factor provides “a robust and highly available platform in an elegant style that reduces footprint, simplifies installation and maintenance, and provides the benefits of a Series C controller design and vertical cabinet positioning. provides efficient heat dissipation for longer life ", while" redundant components and no single backplane provide a solution without a single point of failure. " Nevertheless, despite all the ^{advantages listed in brochure 5,} if you look at the photo of ⁶ control modules and I / O modules of the "Series C" series located in an electrical cabinet, you can see that since each module is located on its own individual board, which looks like a flat plate a sufficiently large perimeter, a small number of boards with modules can be placed in the cabinet. In addition, if we consider examples ^{7 of} fastening such a widely used SFP module ⁸ (English Small Form-factor Pluggable) on a rather flat individual board, we can see that for this they use a proprietary cover, which is used to cover and fix the SFP module located on the board. , and which is rigidly fixed to the board with a screw. Consequently, the design of the slot and the SFP-module located in it, which provides for a quick "hot" replacement of the SFP-module, in this case loses its relevance.

As an analogue of ⁹ for the claimed controller, you can specify the multifunctional controller MFK 1500 based on the CPU715 series CPU module. The known controller has a modular design and contains a main section, in which one or two CPU modules and I / O modules are located on the chassis. The controller may contain at least one remote section, in which one or two interface modules and I / O modules are located on the chassis. The communication between the CPU module and the remote section is carried out via duplicated buses, for which interface connectors are located on the front wall of each CPU module. Also on the front wall of the CPU module there are interface connectors for buses intended for communication with the upper-level system (hereinafter VCA) of the APCS. There is also an interface connector for the communication bus with an external device, such as an operator panel.

As a prototype ¹⁰ for the claimed controller, the REMIKONT R-400 multipurpose controller is adopted. The known controller has a modular design and contains a block of base modules (BBM) and an input-output station (s) for communication with sensors and actuators. Each of the input-output stations contains interface communication modules (MIS) and input-output modules (USO) of various types. The MIS module supplies power to the USO modules and provides communication with the USO modules using the MODBUS protocol and communication with the BBM unit using the I ² C or PROFIBUS protocols. The BBM unit, which is the core of the controller, consists of a set of modules: a processor module, a network module, an interface communication module with a proprietary protocol, an interface communication module of the PC / 104 standard, a stabilized power supply module, a basic communication module, and a basic display module.

The technical problem is to expand the arsenal of tools for industrial programmable controllers.

When creating a new powerful processor unit of the controller, the task was to integrate it into the PTK ² TEKON, which provided the opportunity to use I / O modules of different series of controllers developed by the TEKON group of companies. For this, the processor unit contains a sufficient number of different types of interface connectors, including those in the form of SFP modules, while the design of the processor unit meets modern aesthetics requirements, i.e. it is compact and symmetrical.

The technical result is achieved in that the programmable controller contains a processing unit, at least one local section containing at least one chassis with input-output modules and at least one remote section containing at least one chassis with at least one interface module and with I / O modules. The processor unit consists of a CPU module attached to a chassis or two redundant CPU modules attached. For this, the chassis has mechanical and electrical connectors on the front wall. Also, the processor unit chassis has interface connectors for redundant buses intended for communication with the local section chassis. Each CPU module has interface connectors on the front wall. At least two of the interface connectors on the front of the CPU module are dedicated to redundant buses for communication with an interface module in the remote section. At least two more of the interface connectors on the front wall of the CPU module are intended for redundant buses intended for Ethernet communication with the upper level of the process control system. At least two more interface connectors on the front panel of the CPU module are in the form of SFP modules and are intended for inter-controller data exchange.

For the following description of the controller, the following drawings are given:

fig. 1 is an example of the arrangement of a controller, the processing unit of which has one CPU module;

fig. 2 is an example of a controller arrangement with redundant CPU modules in a processor unit;

fig. 3 - controller processor unit with one CPU module;

fig. 4 - controller processor unit with redundant CPU modules;

fig. 5 - controller processor unit;

fig. 6 - controller processor unit with one CPU module with a door.

Controller 1 (Fig. 1) MFC1500 ^® contains a processor unit 2 and contains a local section 3 and / or a remote section 4. There can be two local sections 3 (Fig. 2), and the number of remote sections 4 is not more than seventeen. The processor unit 2 consists of chassis 5 and the first CPU module 6 of the CPU850 series (Fig. 3) or located on the chassis 5 of the first 6 and second 7 redundant CPU modules (Fig. 4). The CPU module is used in the controller as a central computing device. The local section 3 consists of at least one chassis 8 with I / O modules 9. The remote section 4 consists of at least one chassis 10 with one or two redundant interface modules 11 and with I / O modules 12. It should be noted here that Both in the local section 3 and in the remote section 4 I / O modules of any of the series ^{1 of} controllers developed by the TEKON group of companies can be used. If there are several chassis in one section, they are interconnected by extension cables 13 of the trunk. Data exchange between the processor unit 2 and the local section 3 is carried out via duplicated CAN buses 14 using the proprietary Unitbus protocol. To exchange data between the processor unit 2 and the local section 3 via duplicated buses 14, the M-LVDS technology and TMV proprietary protocol can be used. Data exchange between the processor unit 2 and the remote section 4 is carried out via duplicated buses 15 of the Ethernet network. The interface module 11 provides communication with the processor unit 2 using the proprietary MC1500 protocol and provides communication with the I / O modules 12 using the proprietary Unitbus or TMB protocols. The communication of the processor unit 2 with the SVU 16 of the APCS is carried out via the duplicated buses 17 of the Ethernet network. If there are several remote sections 4, switches 18 are used (Fig. 2). In the redundant mode of CPU modules, chassis 5 installs two CPU modules, while data exchange between the CPU modules occurs via buses located on the printed circuit board of chassis 5. On the front wall of chassis 5, for connection to each of the CPU modules (Fig. 5), there are two electrical signal connectors 19 and 20, a connector 21 for power supply, two stops 22 and 23 and a mechanical connector (latch) 24. Also on the front wall of the chassis 2 there are two pairs of interface connectors (25, 26 and 27, 28) of the 8P8C type, intended for buses 14 for connecting the first and second local sections 3. On the front wall of the chassis 2 there are two connectors 29 for power supply. For high reliability, the chassis are designed as simply as possible: there are no active elements, power circuits and buses are duplicated. On the front wall of each CPU module there is an indicator board 30, a three-position switch 31 for operating modes of the CPU module, a button 32 for setting the default settings (factory settings) of the CPU module (hereinafter "DEF" button) and a slot 33 for an SD memory card.

The front panel of each CPU module has the following interface cable connectors:

- two connectors 34 and 35 for RS-485 communication, intended for connecting external devices (operator panels, frequency converters, a second non-redundant controller, etc.);

- two connectors 36 and 37 of the 8P8C type for Ethernet 100 / 1000Base-T communication for buses 17, intended for communication with the VCA APCS;

- two connectors 38 and 39 of the 8P8C type for Ethernet 100 / 1000Base-T communication for buses 15, intended for connecting remote sections 4.

Under the display panel 30 is a door 40 (Fig. 6), behind which the CPU module has two holders (slots) intended for SFP modules 41 and 42 for Ethernet 100 / 1000Base-T communication or Ethernet 1000Base-FX communication. These connectors are intended for inter-controller communication buses when redundant controllers or are intended for data exchange with other devices.

When the controller is operating, a signal is sent from the sensors to the input modules of the local 3 or remote 4 sections, where it is converted into digital format and digitally transmitted to the CPU module 6, where it is processed and then the processing result is transmitted to the output modules of the corresponding sections of the controller. In turn, the output modules transmit the control signal to the actuators. The operating mode of the CPU module (controller) is determined by the position of the switch 31 on the CPU module and the "DEF" button 32. In the case of redundant CPU modules, the operating mode of the controller is determined by the position of switches 31 on both CPU modules. Switching modes "MASTER" / "SLAVE" is performed manually with the switch 31 or automatically. The mode switching mechanism is implemented in the SPO of the CPU module. To switch modes manually, a key is inserted into the switch 31, one of the three switch positions is set corresponding to the specified mode, and the CPU module is rebooted.

Description of the modes of operation of the CPU module without redundancy:

RUN mode: the application is running (process control is in progress), all configured services, controller diagnostics, Plug & Play service of the modules are running.

In case of redundancy, the CPU module decides on the choice of the "MASTER" / "SLAVE" operating state depending on the diagnostic results. In the "MASTER" state, the controller resources are fully managed (process control). In the "SLAVE" state, the application in the CPU module is executing, but the controller is not being controlled. In this case, the CPU module is ready to switch to the "MASTER" mode (if there are no faults).

PRG Mode (Configuration): Application execution stopped, outputs disabled, CPU module is in configuration (programming) mode.

DEF mode (auxiliary mode): used to restore the factory configuration (for example, to restore a forgotten or incorrectly set IP address).

By manually moving the switch to the "LOCK" position (short for Lock out), the "MASTER" mode is blocked, the application program in the CPU module continues to run, but the control outputs are blocked.

Bibliography

1. N.N. Sergienko, V.V. Skorokhodov. PLC TEKON for critical applications // ISUP magazine, No. 4 (24), 2009. The exact address of the article: https://isup.ru/articles/4/410/

2. B.C. Serezhkin. Highly reliable APCS based on PTK "TEKON" for objects of large and small power engineering // Mining information and analytical bulletin (scientific and technical journal). - Publisher: Limited Liability Company "Gornaya Kniga" (Moscow). - 2014. - No. 5. - S. 182 - 189.

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PN-07-31 ENG December 2007 Honeywell International Inc., page 1-5.

The exact address of the product information:

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The exact address of the product information:

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PN-12-49-ENG November 2012 Honeywell International Inc.

The exact address of the product information:

6. Honeywell launches latest DCS, 30 APR 2014.

The exact address of the article in the journal:

7. Experion PKS, Release 501, Control Firewall User's Guide, EPDOC-XX20-en-501B, April 2018, Honeywell International Inc, page 17.

The exact address of the product information:

https://www.nexinstrument.com/assets/images/pdf/CC-PCF901.pdf

8. The exact address about the product: https://ru.wikipedia.org/wiki/SFP

9. Multifunctional controller MFK 1500. Operation manual. Part 1. General information about the controller.

DARTS.420002.003 RE1, Moscow, 2014, page 20, figure 1.7

Exact address about the product:

https://docplayer.ru/29581023-Mnogofunkcionalnyy-kontroller-mfk1500.html

10. Utility model patent RU No. 115939 U1.

Claims (1)

A programmable controller containing a processing unit and at least one remote section containing at least one chassis with at least one interface module and with input-output modules, characterized in that it further comprises at least one local section containing at least one chassis with input-output modules, while the processor unit consists of a chassis and a CPU module fixed to the chassis or two redundant CPU modules fixed to the chassis, for which the chassis has mechanical and electrical connectors on the front wall, while the processor chassis the unit additionally has interface connectors intended for duplicated buses intended for communication with the local section chassis, and each CPU module has interface connectors on the front wall, at least two of which are intended for duplicated buses intended for communication with the interface module remote section, and at least two of which are intended for duplicated buses intended for communication with the upper level system of the APCS, and at least two more interface connectors on the front wall of the central processor module have the form of SFP modules and are intended for inter-controller exchange data.

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